Shoe cushioning system and related method of manufacture

ABSTRACT

A footwear cushioning system including an insole and a midsole that define a chamber containing multiple, hollow, inverted, truncated cones. The insole includes a plate having a downwardly extending rib to define a recess. The midsole includes a midsole plate including an upwardly extending wall and multiple upwardly opening hollow, inverted frusto-conical cushion cells. The wall interfits within the rib, and the cushion cells abut against the insole plate. An outsole shell is direct-attached to the cushioning system with polyurethane. Preferably, the polyurethane pre-compresses the cushion cells and adds cushioning and energy return characteristics. To assemble the cushion system, an upper is stapled to the insole rib. The midsole is interfitted within the rib. The insole and midsole are heated to fuse the cushion cells to the insole. Polyurethane is poured into the outsole shell and the shell is direct attached to the upper/cushioning system.

BACKGROUND

[0001] The present invention relates to footwear and, more particularly,to a footwear construction and the method for making the same.

[0002] In the footwear industry, there is an ongoing effort to producefootwear including a cushioning system that provides both energy returncharacteristics and a high level of comfort for wearers. The need toproduce such a cushioning system is particularly pronounced in thedesign of work, walking and athletic footwear, where reduction offatigue and increased cushioning are primary objectives. For example, tominimize the effects of standing for long periods on hard surfaces(e.g., concrete floors) and walking on such surfaces, it is desirable toprovide footwear that cushions the wearer's foot from the hard surfaceand also returns energy to the wearer during walking or running.

[0003] Conventionally, energy return and cushioning have been competinginterests. Efforts to improve cushioning typically reduce energy return.One shoe sole assembly used to improve cushioning, disclosed in U.S.Pat. No. 5,233,767 to Kramer, includes multiple, hollow, uniform,vertical columns, which compress and bulge to provide shock absorptionand, therefore, cushioning. Although the use of the uniform, verticalcolumns increases cushioning, energy return is sacrificed because theuniform, vertical columns may not rapidly snap back from the bulgedshape after compression. In another footwear construction, disclosed inU.S. Pat. No. 6,131,310 to Fang, a flanged insole is positioned over anoutsole including solid, cylindrical separating posts, but the insole isgapped a distance above each post. This structure increases cushioningdue to the compression of the separating posts, however, energy returnis lost because the columnar cylindrical posts may not rapidly snap backinto pre-compression shape. Moreover, after the insole separates fromthe separating posts when weight is removed from the shoe, theseparating posts cannot generate return energy to the insole due to thephysical separation.

[0004] Although the cushioning systems of the prior art providecushioning, there remains a long felt and unmet need for a footwearconstruction that provides a desired level of cushioning as well asenergy return.

SUMMARY OF THE INVENTION

[0005] The aforementioned problems are overcome in the present inventionwhich provides multiple, inverted, frusto-conical cushion cells disposedbetween an insole and midsole. The cushion cells are preferably mountedto or integral with the midsole. The insole preferably includes a ribextending around it to form a recess into which the midsole is nested toform an enclosed cushion system.

[0006] In a preferred embodiment, the rib of the insole is secured to anupper. An outsole shell, filled with polyurethane, is direct-attached tothe insole and/or the upper. Preferably, the polyurethane exerts apressure against the midsole, forcing the cushion cells firmly upwardagainst the insole. The insole also may include multiple vent holes,each uniquely associated with one of the cushion cells to provide a ventfor air to escape the cells during compression and enhance theshock-absorbing characteristic of the cells.

[0007] In another preferred embodiment, multiple cushion cells arepositioned at the forefoot of the cushioning system and aligned with themetatarsal heel of a wearer. Another cushion cell is disposed under theheel of the cushioning system. This cushion cell is concentricallydisposed in a vertical, cylindrical wall that extends from the midsolebase.

[0008] The cushioning system of the present invention is preferablymanufactured using the general steps of (a) securing an upper to aninsole, the insole including an insole base formed in the shape of afoot and a rib that define a recess and (b) positioning a midsole in therecess where the midsole includes a midsole base and multiple upwardlyopening, truncated cones integral with the midsole base, so that thelargest diameter portion of the truncated cones abuts the insole base.

[0009] Footwear incorporating the cushioning system of the presentinvention is preferably manufactured using the general steps of (a)securing an upper to an insole where the insole includes an insole baseand a rib that together define a recess; (b) positioning a midsole inthe recess, the midsole including a wall extending from the midsole andmultiple, hollow, inverted truncated cones and (c) securing a sole to atleast one of the upper, the insole, and the midsole.

[0010] The present invention provides a unique footwear constructionhaving a previously unachieved combination of cushioning and energyreturn. The interaction of the cushion cells sandwiched between theinsole and midsole provide a unique structure that has the ability toboth (1) compress and provide cushioning and (2) provide maximizedenergy return upon decompression of the cells. Furthermore, when thecushioning system is incorporated into a shoe and the filler materialpre-loads the cushion cells, additional energy return is available fromthose cells because their upwardly opening walls are slightlypre-compressed.

[0011] These and other objects, advantages and features of the inventionwill be more readily understood and appreciated by reference to thedetailed description of the preferred embodiments and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is an exploded perspective view of an article of footwearincorporating the cushioning system;

[0013]FIG. 2 is an exploded section view of the article of footwear withan upper attached to an insole; and

[0014]FIG. 3 is a sectional view of the article of footwearincorporating the cushion system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] A boot constructed in accordance with a preferred embodiment ofthe present invention is shown in FIGS. 1-3 and generally designated 10.For purposes of disclosure, the present invention described inconnection with a conventional three-quarter height boot. As will beappreciated, the present invention is well suited for use with othertypes of soled footwear.

[0016] Generally, the boot 10 includes an upper 12 that is secured tothe outsole shell 20 by a welt 16 and insole rib 64. The outsole shell20 defines a void 22 that contains a filling material 24, such aspolyurethane, polyvinyl chloride, or thermo plastic rubber. The welt 16is attached to and interconnects the upper 12, the insole 60 and theoutside shell 20.

[0017] The upper 20 is conventional and will only be described brieflyhere. Upper 12 includes a quarter 29 and a vamp 28. The upper 12terminates in the lower peripheral edge 26, which is attached to theoutsole shell 20 through the welt 16 as described in detail below. Theupper 12 is preferably manufactured from leather, canvas, nylon or othersuitable materials, and may include a liner (not shown) or otherconventional accessories.

[0018] The welt 16 extends entirely around the boot 10 to interconnectthe upper 12 and the outsole shell 20 as best shown in FIG. 3. The welt16 is generally conventional, including a generally horizontal baseportion 32 with an upwardly extending upper rib 34 located toward thecenter of the base portion 32 and downwardly extending lower rib 36located at the inner edge of the base portion 32. The outer surface ofthe upper rib 34 is rounded to, among other things, reduce the profileof the welt 16. The lower rib 36 is generally rectangular in crosssection and is of an sufficient size to receive staples, stitching orother fastening elements. The horizontal base portion 32 defines anupwardly opening stitch grove 38 that extends around the welt 16 nearits outer edge. The stitch grove 38 is adapted to receive the stitching72 that interconnects the outsole shell 14 and welt 16 as described inmore detail below. Optionally, the stitching 72 and stitch grove 38 maybe absent from the footwear as desired.

[0019] As noted above, the cushioning system generally includes theinsole 60 and midsole 40 and cooperating filling material 24, which maybe polyurethane, polyvinyl chloride or thermo plastic rubber. Ifdesired, the cushioning system may also include a shank 67 incorporatedinto the insole 60.

[0020] The insole 60 is includes an insole base 62 with a downwardlyextending rib 64. The insole base 42 is generally planar and correspondsin shape with an outline of a foot. The insole rib 64 extends downwardlyand around the insole base 62 at or near its outer edge or periphery.The insole rib 64 and insole base 62 cooperate to form a downwardlyopening recess 66. The insole rib is of sufficient size to receivestaples, stitching or other fastening elements.

[0021] Preferably, the insole base 62 defines a plurality of holes 68,each being uniquely associated with and preferably concentricallypositioned over a corresponding cushion cell 42 described further below.Optionally as desired, the holes 68 may be absent from the insole 60.Additionally, a reinforcement shank 67 made from plastic, metal or othermaterials may be secured to or integral with the insole to add rigidityto the shoe 10. Among other things, this permits control of the amountof pre-compression applied to the cushion cells.

[0022] The midsole 40 generally includes a midsole base 46, upwardlyextending wall 44 and cushion cells 42. The midsole base 46 is generallyplanar and corresponds in shape with the outline of the foot. Themidsole wall 44 extends upwardly from and around the midsole base 46 ator near its outer edge. The outsole wall 44 preferably extends an equaldistance from the midsole base 46 as the cushion cells 42. Together, thewall 44 and midsole base 46 form a cavity 47 in which the cushion cells42 are disposed. The cells 42 are preferably integrally molded orsecured to the midsole base 46. The cushion cells 42 are essentiallyhollow and are of an upwardly opening frusto-conical shape. Describedanother way, the cushion cells 42 are in the shape of hollow, inverted,truncated cones, tapered so that the cell base 41 is of smaller diameterthan the upper cell portion 43. Although the cushion cells 42 arepreferably an inverted, truncated cone, they may be of virtually anysimilar tapered shape, such as cylindrical (not shown) or hemispherical(not shown).

[0023] With particular reference to FIG. 3, the midsole wall 44 fitswithin the insole rib 64 to define a cavity therein. The cushion cells42 extend from the midsole base 46 to abut against the insole base 62.Preferably, the upper portion 43 of the cushion cells 42 are heat-fusedto the midsole base 62 so that the insole/midsole and related componentsform a cushion layer 70. The elements of the cushion layer preferablyare constructed of a semi-supple material, for example, rubber orsynthetic elastomers.

[0024] Preferably, the cushion cells are positioned on the midsole base46 aligned with the bones in the feet, particularly the metatarsal head.As shown in FIG. 1, a single cushion cell 42 may be disposed on themidsole base 46 in the area corresponding to the heel of a wearer.Optionally, a vertical wall 48 may be positioned concentrically aroundthe cushion cell to add additional support and cushion in the heel. Aswill be appreciated, additional cushion cells may be disposed in theheel. Furthermore, the cushion cells may be of varying sizes and locatedin different portions of the midsole as desired.

[0025] The outsole shell 20 is preferably manufactured from a relativelyhard rubber or other sufficiently durable and wear-resistant material.The outsole shell 20 generally includes a bottom 56 and an peripheralwall 58 extending upwardly from the periphery of the bottom 56. Thebottom 56 includes an inner surface 50 and an outer surface 52 whichforms the wear surface of the outsole shell 20. The outer surface 52may, as desired, be contoured to define the desired heel and treadpatterns. The outer surface 52 may also be textured as desired toimprove the traction and esthetic appeal of the footwear. The peripheralwall 58 also includes an inner surface 54 and an outer surface 55. Theouter surface 55 of the peripheral wall 58 may be contoured or texturedto provide the desired visual appearance. The outer surface 55 alsodefines and an outwardly opening stitch groove 57, which extends aroundthe peripheral wall 58 near its upper edge. The stitch groove 57 isgenerally rectangular in cross section, however, any desired crosssection may be used. The peripheral wall 58 may include a plurality ofprotrusions (not shown) that extend inwardly to interlock with filler 24and improve the interconnection of the various sole components.

[0026] The filling material 24 is preferably conventional polyurethanefoam, however, other materials such as polyvinyl chloride and thermoplastic rubber may be used as well. The inner surface 50 of the outsoleshell 20 and the inner surface 54 of the peripheral wall 58 cooperate todefine a void 22 that receives the filling material 24. As describedbelow, the filling material 24 is preferably pour molded into the void22 during assembly of the footwear 10 such that it expands to flowaround and interlock the insole base 46 and upward around the insole rib64 and partially adjacent the midsole wall 40 to interlock to the insoleand midsole and the outsole shell 20.

[0027] Preferably, as best depicted in FIG. 3, upon expansion, thepolyurethane presses upward against the midsole base 46 therebypre-compressing the cushion cells 42 between the insole base 62 and themidsole base 46. As can also be seen in FIG. 3, the areas around thecushion cells 42 upwardly bow to a slight degree because of the expandedpolyurethane 24. The density and precise chemical makeup of thepolyurethane will vary from application to application depending on avariety of factors, including the size of the void 22 and the desiredcushioning and flexibility characteristics. Among other things, thispermits control of the amount of pre-compression applied to the cushioncells.

Manufacture and Assembly

[0028] The boot 10 is manufactured using generally conventionalmachinery. More specifically, the upper 12 is manufactured usinggenerally conventional techniques and apparatus. The desired uppermaterial (not shown) is cut to form the various elements of the upper,including the vamp 28 and quarter 29. The elements of the upper are thenfitted and sewn together using conventional methods and apparatus. Alining (not shown) may be sewn within the upper during the fitting step.The fitted upper 12 is stretched over a last (not shown). The insole 60is placed within the lower peripheral edge 26 of the upper usingconventional apparatus and techniques. The insole rib 64 is stapleddirectly to the lower peripheral edge 26 with staples 27. Alternatively,insole rib 64 can be sewn or glued to the upper 12 in a conventionalmanner.

[0029] The welt 16 is manufactured using conventional techniques andapparatus. For example, the welt 16 can be extruded from hard durablerubber. Once the upper 12 is lasted to the insole 60, the welt isattached to the upper 12 and insole 18. Specifically, lower welt rib 36is stitched around the peripheral edge 26 of the upper 12 and the insole18 using conventional apparatus and techniques. This rib stitch 35preferably extends through the lower welt rib 36, the lower peripheraledge 26 of the upper 12, and the insole rib 64. If desired, a filler(not shown), shank (not shown) or other conventional sole component canbe cemented or integrally incorporated into the bottom surface of theinsole base 62 using conventional adhesive, cementing or fusingtechniques.

[0030] The midsole 40 is manufactured using conventional techniques andapparatus. The outsole shell 40 is preferably injection or pour moldedto form a supple yet durable upper using conventional molding apparatus.The midsole 40 can, however, be manufactured from other durable andsupple materials. Preferably, the cushion cells 42, vertical wall 44 andvertical concentric wall 48 (if used) are all formed during the moldingoperation to form an integral part of the midsole 40. Optionally,however, each cushion cell may be cemented or otherwise secured to theinsole base 46 as desired. Each of the cushion cells preferably ismolded so that they align with and generally correspond to themetatarsal head and heel of a wearer's foot. As will be appreciated, thecushion cells 42 may be distributed in any pattern as desired dependingon the intended use of the footwear.

[0031] A manufactured insole 40 is positioned within the recess 66 ofthe insole 60. Preferably, the midsole wall 44 interfits within theinsole rib 64 with low tolerances therebetween. The upper portions 43 ofthe cushion cells 42 also preferably abut against the insole base 62when the midsole 40 is positioned within the recess 66. The cushioncells also preferably align and are uniquely associated with each of theplurality of holes 68 in the insole 60. After the midsole 40 isinterfitted in the insole 60, the components thereof are integrallyfused together using heat application. Preferably, the two materials areconstructed of like material that bonds to one another with heat, forexample, rubber, synthetic elastomers, ______ [Larry, please provideacceptable materials]. Optionally, the uppermost portions of the cushioncells 42 and, as desired, the midsole wall 44 may be cemented to theinsole base 62 and insole rib 64 as desired. In this manner, a completedcushioning system element 70 is formed. As will be appreciated, themidsole and outsole may be molded as a single piece (not shown) whereinthe insole plate 62 is secured to the midsole base 46 via the cushioncells 42 and a single outer peripheral wall (not shown). Optionally, acushioning rib (not shown) may extend below this midsole base 46 tofacilitate fastening to the peripheral edge 26 of the upper.

[0032] In the preferred embodiment of FIGS. 1-3, the outsole shell 20 ismanufactured using conventional techniques and apparatus. The outsoleshell 20 is preferably injection or pour molded to form a hard, durablerubber using conventional molding apparatus. The outsole shell 20 can,however, be manufactured from other durable outsole materials. Thestitch groove 57, void 22 and desired tread pattern are formed duringthe molding operation as an integral part of the outsole shell 20.

[0033] After the outsole shell is manufactured, it is attached to theupper/welt/cushioning system combination. Machinery used preferablyincludes a die (not shown) that facilitates assembly of the boot 10. Thedie includes a top half, which receives the upper/welt/cushioning systemcombination and a bottom half, which receives the outsole shell 20. Diehalves are designed such that they can be closed to fold theupper/welt/cushioning system combination in appropriate alignment withthe outsole shell 20. The die holds the bottom surface of the welt 16against the top surface of the peripheral wall 58 firmly enough toprevent expanding polyurethane from entering the seam and/or exiting outover the sides of the peripheral wall 58.

[0034] After the outsole shell 20 and the upper/welt/cushioning systemcombination are inserted in the appropriate die halves, the appropriatevolume of a filler material, preferably polyurethane foam, is pouredinto void 22. As the polyurethane foam is poured into the void 22, itbegins to expand and cure. The dies immediately close, bringing theupper/welt/cushioning system combination in a proper alignment with theoutsole shell 20. The polyurethane foam continues to expand and cure,causing it to surround, trap and interlock the various elements,including the midsole and the welt. By virtue of its expansion, thepolyurethane foam flows into the seams between the welt 16, upper 12,insole rib 64 and midsole wall 44 and into the stitch holes in therespective elements. As a result, the polyurethane filling material 24secures the outsole shell to the upper/welt/cushioning system.

[0035] Preferably, enough polyurethane foam is disposed in the void 22so that when it expands and cures against the cushioning system 70, inparticular, the midsole base 46, it pushes upward against the base,causing slight upward deformation 45 as depicted in FIG. 3 around eachof the cushion cells 42. In turn, this causes the cells to be slightlypre-compressed, which adds to the cushioning and energy returncharacteristics of the cushioning system.

[0036] Polyurethane foam is generally well-known in the footwearindustry and, therefore, will not be described in detail. Suffice it tosay that polyurethane foam is typically derived from combining apolyether, such as polypropylene glycol, with diisocyanate in thepresence of water and a catalyst. The resulting chemical reactionproduces carbon dioxide which causes the polymer to foam. The rigidityand flexibility of the polyurethane foam can be varied from applicationto application as desired using a variety of well-known techniques, suchas by adjusting the type and a portion amount of the reactants. Inaddition, the rigidity and flexibility of the polyurethane foam can bevaried by adjusting the volume of polyurethane foam deposited in thevoid 22.

[0037] After the filling material 24 is sufficiently cured, the weltoptionally is stitched directly to the outsole shell 20 usingconventional machinery. The outsole stitch 72 extends around theperiphery of the boot 10 through the welt 16 at stitch groove 38 in theoutsole shell 20 at stitch groove 57. The stitches 72 are recessed inthe grooves 38 and 57 so that they are protected from abrasion and wear.Preferably, the outsole stitch 72 does not pass through the fillingmaterial 24.

[0038] Finally, a number of conventional finishing operations areperformed on the boot 10. For example, the edge of the sole 14 istrimmed and shaped; the upper 12 is cleaned, polished and treated asappropriate and necessary; and the laces are inserted in the eyelets.

[0039] The above descriptions are those of the preferred embodiments ofthe invention. Various alterations and changes can be made withoutdeparting from the spirit and broader aspects of the invention asdefined in the appended claims, which are to be interpreted inaccordance with the principles of patent law including the doctrine ofequivalents. Any references to claim elements in the singular, forexample, using the articles “a,” “an,” “the,” or “said,” is not to beconstrued as limiting the element to the singular.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A cushioning system forfootwear comprising: an insole including an insole plate defining aperiphery and a first wall extending downwardly from said insole plateto define a first recess; a midsole including a midsole plate, a secondwall extending upwardly from said midsole plate to define a secondrecess and a plurality of cushion cells integral with said midsole plateand located within said second recess, said cells in the shape ofhollow, truncated cones extending in an upwardly opening manner fromsaid midsole plate, wherein said midsole is at least partiallyinterfitted in said first recess so that said insole plate abuts saidplurality of cushion cells.
 2. The cushioning system of claim 1 whereina plurality of said cushion cells are aligned with the metatarsal headof a foot of a wearer of footwear including the cushioning system. 3.The cushioning system of claim 2 wherein at least one of said cushioncells is aligned with a heel of the foot of the wearer.
 4. Thecushioning system of claim 3 wherein a support flange is disposedconcentrically about said cushion cell aligned with the heel of the footof the wearer.
 5. The cushioning system of claim 1 wherein said cushioncells, insole and midsole are constructed of a supple material selectedfrom the group of consisting of rubber and synthetic elastomers.
 6. Thecushioning system of claim 1 wherein the insole plate defines aplurality of vent holes, each of which is uniquely associated with eachof the plurality of cushion cells.
 7. The cushioning system of claim 1wherein the insole is attached to an outsole shell to define a voidbetween the midsole plate and the outsole shell.
 8. The cushioningsystem of claim 7 wherein the void is filled with a filler chosen frompolyurethane, polyvinyl chloride and thermo plastic rubber, wherein thefiller is direct-attached to the insole plate and the outsole shell andwherein the filler is cured in-situ within the void.
 9. The cushioningsystem of claim 8 wherein the filler material presses against the bymidsole plate so that the cushion cells are firmly abutted against saidinsole plate to pre-load the cushion cells.
 10. The cushioning system ofclaim 9 wherein said midsole plate deflects upwardly between each ofsaid plurality of said cushion cells.
 11. The cushioning system of claim8 wherein said first wall and said second wall are positioned adjacentone another to prevent the filler entering the first and secondrecesses.
 12. An article of footwear comprising: an upper including alower peripheral edge; an insole including a first plate and a ribextending from said first plate defining a first recess, said ribsecured to said lower peripheral edge; an insert including a secondplate, a flange extending from said second plate and a plurality ofhollow, upwardly and outwardly tapering members extending from saidsecond plate, said insert positioned within said first recess to definea cavity between said first plate and said second plate; and a solehaving a filler material and an outsole shell, said filler materialdirect-attached to at least one of said upper, said insole and saidinsert, said outsole shell defining a void filled with said fillermaterial.
 13. The footwear of claim 12 wherein said first plate definesa plurality of apertures, each corresponding to at least one of saidplurality of hollow, upwardly and outwardly tapering members.
 14. Thefootwear of claim 13 wherein said filler material is bonded directly tosaid insert and said outsole shell, said filler material forming amajority of said sole.
 15. The footwear of claim 11 wherein said firstplate includes a shank to provide support for the foot of a wearer. 16.The footwear of claim 11 wherein the plurality of hollow, upwardly andoutwardly tapering members align with metatarsal bones of the foot of auser and wherein at least one of the members corresponds to the heel ofa wearer.
 17. The footwear of claim 11 wherein each of the plurality ofhollow, upwardly and outwardly tapering members includes a base portion,which is integrally molded with the second plate, and a contact portion,distal from said base portion, wherein said contact portion abutsagainst said first plate when said insert is positioned within saidfirst recess.
 18. A method for manufacturing footwear comprising:securing an upper to an insole, the insole including an insole plate anda rib, the insole plate and rib defining a recess; providing a midsoleincluding a midsole plate, a wall extending from the midsole plate, anda plurality of hollow, inverted, truncated cones integral with andextending from the midsole plate; positioning the midsole within therecess wherein the wall locates the insert by cooperating with the rib;and securing a sole to at least one of the upper, the insole and themidsole.
 19. The method of claim 18 wherein the sole includes an outsoleshell, that is secured to at least one of the upper, the insole and themidsole.
 20. The method of claim 19 wherein a cavity is formed betweenthe outsole shell and the midsole.
 21. The method of claim 18 comprisingdisposing a filler within the cavity so that the midsole plate is forcedtoward the insole plate, thereby firmly pressing the hollow, inverted,truncated cones against the insole plate.
 22. The method of claim 18comprising heating the midsole and insole so that a portion of thehollow, inverted, truncated cones is bonded to the insole plate.
 23. Themethod of claim 18 wherein the wall interfits within the rib.
 24. Themethod of claim 20 wherein the filler is a material selected from thegroup consisting of polyurethane, polyvinyl chloride and thermo plasticrubber.
 25. The method of claim 23 wherein the insole plate defines aplurality of apertures, each of the apertures aligned with each of theplurality of hollow, inverted, truncated cones to provide a vent wherebyair entrapped within the hollow, inverted, truncated cones may bedispelled when the cones are compressed.
 26. The method of claim 24comprising securing a shank to the insole plate to provide rigidity tothe insole.
 27. A method of manufacturing a footwear cushioning systemcomprising: securing an upper to an insole, the insole including a firstplate member and a rib, the rib and first plate member defining arecess; and positioning a midsole within the recess, the midsoleincluding a second plate member and a plurality of upwardly-opening,truncated cones secured to or integral with the second plate member,wherein a most-open portion of the truncated cones is adjacent the firstplate member.
 28. The method of claim 26 comprising: partially fillingan outsole shell with a cushioning filler; clamping at least one of theupper, midsole and insole into registration with the partially filledoutsole shell; and allowing the cushioning filler to cure in-situwhereby said cushioning filler is bonded directly to at least one ofsaid midsole, insole and upper.
 29. The method of claim 28 comprisingsecuring a welt to at least one of the rib and the upper, the welt beingexternal to the recess.
 30. The method of claim 29 comprising stitchingthe outsole shell to the welt.
 31. The method of claim 30 comprisingheating the insole and midsole to fuse the most-open portion of theupwardly-opening truncated cones to the first plate member.
 32. Themethod of claim 28 wherein the cushioning filler is a material chosenfrom the group consisting of polyurethane, polyvinyl chloride and thermoplastic rubber.
 33. A footwear cushion system comprising: an insole; amidsole, said insole and midsole cooperating to define a cavity; aplurality of inverted, frusto-conical cells disposed in said cavity; anoutsole shell secured to at least one of said insole and midsole todefine an outsole chamber; and an expandable filling material curedin-situ within said chamber whereby said plurality of invertedfrusto-conical cells are pre-loaded by being pre-compressed between saidinsole and midsole within said cavity.
 34. The footwear cushion systemof claim 33 wherein said cushion cells are integrally fused to saidinsole and midsole.
 35. The footwear cushion system of claim 33 whereinone from said plurality of cushion cells is disposed in a heel portionof the insole, and wherein a cylindrical wall is concentrically disposedaround said one cushion cell.
 36. The footwear cushion system of claim35 wherein said insole includes an integral shank to add rigidity to thefootwear cushion system.
 37. The footwear cushion system of claim 36wherein the insole defines a plurality of air vents, each uniquelyassociated with one of said plurality of cushion cells.